Casing for mattresses and the like



May 21, 1940. L. .1. BENNETT CASING FOR MATTRESSES AND THE LIKE Filed March 22, 1937 2 Sheets-Sheet 1 May 2l, 1940. l.. J. BENNETT CASING FOR MATTRESSES AND THE LIKE Filed Marsh 22. 1937 2 Sheets-Sheet 2 I OJ.

Patented May 21, 1940 PATENT OFFICE CASING FOR MATTRESSES ANDI THE LIKE Lewis J. Bennett, Hancock, N. Y., assigner of fifty-five per cent to Ralph W. Tyler, Hancock, N.

` Application March 22, 1937, Serial No. 132,321

12 Claims.

The present invention relates to a casing, cover or envelope and has reference more particularly to a casing, cover or envelope adapted to be used lfor mattresses, hassocks, cushions, pillows and the like.

An object and feature of the invention resides in the provision of a novel casing for a mattress, cushion or the like having a boxing or wall unit comprising a sheet oir-,plate of resilient and ilexi- 'ble material characterized by its self-sustaining properties, being independent of reinforcements or support from the inner filler or core for restoration to its original form and shape.

, Another object is to provide a casing with a ywall unit or boxing made of a material which inherently causes the wall unit or boxing to resist permanent deformation and to maintain its original shape even though subjected to repeated strains resulting from applied compressive forces.

Another object is to provide a casing having a wall unit or boxing which is made of a material, such as spring sheet metal, which requires no additional and separate reinforcing members,

, which possesses smooth edges and surfaces, which =is easy and economical to construct, convenient to detach from the top and bottom covers for repair or replacement of said covers or ticks, `which is neat and ornamentally attractive in appeary ance, as well as clean and sanitary; and which "facilitates convenient accessibility to the ller or core.

Other objects, purposes, advantages, ycapabilities and characteristic features of the present` invention will appear as the description pro- "gresses, during whi-ch reference will be made to the accompanying drawings which show the invention in a manner to make it easily understood rather than with a view of showing the particular ,f detail of construction preferably employed in practice; and in which:

Figure 1 is an enlarged fragmentary exterior view in perspective of a corner unit of the casing, shown fully in Figure 5, constructed in accordl"ance with and embodying a formyof the inven- View in perspective of a corner unit of the casing;

and

Figure 7 is an enlarged side elevation vview in perspective showing a detail variation of a side wall of the casing.

Like reference characters designate the same parts wherever they occur in the several gures.

In the drawings accompanying and `forming part of this specification, certain specific disclosures of the invention are made for purposes of explanation, but it will be understood that the details may be modified in various respects without departure from the broad aspect of the invention.

My invention relates particularly to a casing, cover, protector or envelope used to enclose a ller or core, such as is commonly employed in a mattress, cushion, pillow, hassock and the like. In the accompanying drawings I have illustrated the preferred embodiments thereof, the several viewsillustrating schematically a preferred construction and assembly of the parts constituting the casing.

Referring more particularly in detail ,to the drawings I have indicated the casing, envelope or cover generally by the reference character I0 (see Figure 5). constituted of the customary parts, namely, the

top and bottom portions and the side and endA 30" substantially parallel to and spaced from said'.

top tick and having a laterally disposed boxing The casing II) comprises and isv unit I6 detachably joined or connected with or united to or secured to the roll edges of the top and bottom ticks. The top and bottomV elements or ticks may be made from a single ply (or multi-ply) fabric material of the desired shape and the boxing unit I6 may be a single (or multi-ply) sheet or plate of any suitable resilient (or elastic) and flexible (or yieldable or bendable) material of the desired shape or form, although it is to be clearly understood that multi-ply sheets or layers may be used. The sheet or plate used for the boxing unit may be composed of any suitable material, preferably thin, such as sheet steel' (spring steel resembling and like the steel used in the well known flexible steel tape measuring rules), metal and metal alloys, semi-hard rubber,-

reinforced bersheets or other suitable materials possessing sufficient resiliency and flexibility to satisfy the requirements therefor.

The core or ller (not shown) contained in and surrounded or accommodated by the casingy Ill may be a cushion, pad or a mattress filled with a suitable material such as cotton, kapok, an inflatable unit, inner spring mattress, and. so forth, and may be of any suitable construction since such core or filler forms no part of my invention.

The boxing unit I6 in the illustrated embodiment comprises a pair of side Wall portions or elements indicated at I8, a pair ofend Wall portions or elements indicated at 2l! and four corner units indicated at 22. Although the boxing unit I6 has been preferably represented as comprising and consisting of several sectional elements it is to be clearly understood that the present invention contemplates a boxing unit constructed from a single continuous element or sheet or a plurality of elements providing a sectionalized unit. Thus a single sheet may be stamped or rolled or formed into a suitable boxing unit, the meeting ends thereof being properly united; or several sections may be joined or connected into a unit, each section including a corner and a Wall element (four such sections to constitute a rectangular unit); or individal corner units and several wall sections (similar to disclosed embodiment) may constitute a boxing unit. The several sections of a wall unit mayy obviously each be of the same or Adifferent suitable resilient and flexible material.

The selection of the type of boxing Luiit will depend on the particular needs, materials available, production facilities and costs, and the like; the manufacturing methods of construction known in the art forming no part of the invention and being readily understood by those skilled in the art.

At this point it is desired to explain that the stiffening reinforcements provided on casings for mattresses, cushions and the like as presently employed and known in the art for the purpose of aiding and promoting maintenance of the original shape of the casings possess certain shortcomings or deficiencies which obstruct. complete fulfillment of their intended functions. Transversely positioned stiffeningor reinforcing rods have been secured to the Walls of the boxing and also reinforcing longitudinally extending ribs have also been secured to the walls of the boxing. Stitching in certainr fashions is an additional manner of reinforcing the boxing. A rigid stiifening element of metal, cardboard or wood has been inserted in a pocket in the Walls substantially the size of the Walls.

The present invention entirely overcomes the defects and deficiencies of these reinforcing ele-- ments and provides 'a boxing unit having walls of neat appearance, that is simple to manufacture and capable of permanently maintaining at all times, except when temporarily depressed, its

original shape, form or condition without the aidv of additional reinforcements.

As more clearly shown in Figures l, 2 and 5 each side Wall I8 comprises, in a preferred embcdiment, one piece (single or multi-ply) of metal in the form of a sheet or plate, preferably of a high grade spring steel, of substantially rectangular contour. Since the side walls and the end Walls are similar in construction a description of one will suiiice for all. Each side wall I8 is slightly bent, curved or arcuate, as

yclearly indicated, such that an axis lying in the wall intermediate and parallel to the edges of the Wall assume a ramenant position away from plane passing through a pair of edges of the Wall. As shown the wall is preferably transversely arcuate or bulged slightly. Thus the walls when assembled are exteriorly concave in shape and appearance (or interiorly convex). The purpose of such curvature of the Wall is to assure that the Walls Will bend conveniently to permit the edges thereof to collapse or bend toward each other when temporarily placed under compression.

It is toy be clearly understood, however, that the walls may be exteriorly convex or simply plane, as desired. It is to be further understood that the wall element may take any shape or form desired and be of a suitable nonrectilinear contour or configuration in at least one direction thereof, preferably in a transverse direction, depending on relative lengths and position of the longitudinal and transverse directions as assembled in the boxing unit. Thus the wall element (plate or sheet) may have a form or shape in one direction which is nonrectilinear, noni plane, wavy, sinuous, tortuous, devious, circuitous, serpentine, zigzag or of any other form or a combination of these.

Opposite edge portions of the wall I8 may be rolled or folded away from the convex face thereof (or toward the concave face) in the manner clearly shown so as to form outwardly extending flanges, channels or tubular members 24. The edge of each flange 24k touches or nearly touches the face of the Wall whereby a longitudinally extending slot or slit is formed along the channel or tubular member 24. This slotted or open channel or flange 22 thus constructed is adapted to receive, accommodate and removably ol' dctachably hold the ends of the contiguous and conterminous roll edges of the top and bottom ticks IZ-IL `The ends of the ticks are provided `with a: beaded or corded roll edge (see Figure 2') which consists of a portion of the fabric turned around a cord 26 of cotton, hemp, rubber or other suitable material and this corded edge is inserted by any suitable instrument made for the purpose which grasps the corded edge and is inserted with the corde'dedge into and through the kSlot ofthe channel 24. The instrument is then slid along the channel, the spring action of the channel near the slot permitting the tick roll edge to be inserted into the channel or flange 2li. The roll edge of the tick is thus placedwithin the tubular flanges 24 which'securely hold the f may be employed.

Referring now to the corner section or unit 22 (see Figures 1, 5 and 6), since each corner unit is alike, a description of one Will suffice for all. The corner unit 22 is preferably made from one piece of thin material, such as spring sheet steel, which possesses resiliency and flexibility of a high grade or quality, similar to the one piece wall sheet or plate I8. The sheet is preferably rectangular in the form shown but may assume any desired form.l The longitudinal 0r topy and bottom edges are outwardly bent, rolled or formed into suitable `flanges 32 similar to those formed on the side and end walls |8--28 but of a different size so that the complementary ends of the corner units may be telescopically joined or connected when assembled therewith. `The slot between the end of the flange and the face of the sheet permits reception and accommodation of the beaded roll edge of the tick.

It will be observed that the flanges 32 of the corner unit 22 are `shown provided with strips or fingers 34 cut therein for an appreciable distance either side of the angle of bend therein. Such `preferred provision. of lingers facilitates bending of the corner unit at an angle to form the corner although it is contemplated that the fingers may be omitted, as desired, leaving continuous flanges the full length of thecorner unit.

Apertures 38 have been provided near the transverse ends of the sides of the corner unit to serve as mating locking means for the corresponding member 28 on the side and end walls.

In order to preclude undue buckling, collision or interference of the wall portions of the corner unit when the same is placed under compression temporarily in a partial collapsing action provision has been made in the corner unit at the angle formed by the wall portions 35 thereof by forming openings or apertures 38 therein in such manner as to leave a strip or bar 38 extending transversely of the corner, as clearly indicated. The apertures are shown in the form of a triangle each having its base conterminous with the bar 38 and its apex pointing toward the transverse edge of the corner unit. The aperture may assume any other suitable form however. It is to be clearly understood that any other suitable provision is contemplated in order to permit convenient collapsible bending of the `corner unit for the reasons set forth.

However, such provision of apertures is not essential to the practice of applicants invention and may be dispensed with as desired, as when the corner section of the type of mattress shown as one embodiment of the invention is made of the other nonmetallic and more resilient materials contemplatively falling within the scope of the invention as heretofore specified.

The wall portions of the corner unit are preferably provided with suitable extensions 48 to aiiord greater strength and rigidity of construction at the overlapping union of the corner unit with the complementary ends of the end and side wall sections. Suitable means of a simple character are provided on the wall portions 35 of the corner unit for fastening any suitable cover element, such as textile fabric, rubberized canvas and the like, thereto. This fastening means is shown as made of a plurality of male elements or studs 42 secured to the wall portions which cooperatively mate with corresponding socket members 44 secured to the cover 4t (Figure 5), this fastening means being known as a snap fastener. Obviously any other suitable fastening means may be employed as desired and the stud and socket may be reversed on the walls and cover, the only essential requirement being that suitable fastening means be provided which will permit convenient and ready removal of the cover 46 from the corner unit 22.

The sections of the boxing unit including the two side walls I8, two end walls 28 and the four corner units 22, formed in the shapes and constructions above described, are assembled and joinedor connected together as clearly indicatedtening engagement. Each of the other side and end walls are detachably joined together to effect the assembled boxing unit as shown. The top and bottom ticks are attached to the boxing unit by inserting the stitched beaded or corded roll edges thereof into the slotted resilient and yieldable flanges of the boxing unit, using any suitable instrument for the purpose, in the man ner previously described. The flanges, by virtue of their spring action, close around the tick roll edges to maintain the same taut and smooth.

The ller or core may be placed inside the boxing unit before or after the sections are entirely joined and assembled and the top and bottom ticks, when detachably joined or connected to the boxing unit, will entirely conceal the filler. By such construction applicant has provided an im-l proved, novel, new and useful casing, envelope or cover for a filler or core and which casing will always maintain its original, smooth and taut shape and form without the aid of reinforcing members and independent of any shape-lending assistance from the enclosed and contained filler or core.

It is further contemplated that in cases where a more flexible or yieldable boxing is desirable, such as mattresses or cushions employed for invalids and for other purposes, the boxing unit may be made of a resilient and flexible sheet or plate which has been mutilated in order to increase its spring action and accordingly to decrease its resistance to ilexure or bending.

The modifications in Figures 3 and 4 are intended to serve this purpose. As shown the resilient and flexible thin sheet or plate of metal (such as spring steel), like the sheets previously described, represents a wall section of the boxing unit. This sheet or plate has been stamped (or any other suitable metal working treatment may be used) into the shape indicated so as to possess an arcuate form and perforated so as to produce substantially rectangular apertures 48 (or like a parallelogram or any other suitable shape) in the wall, leaving bars or strips 58 extending 1n one direction thereof (transversely) and interconnecting the longitudinal flanged ends of the wall. By these constructions a more yield-` able or flexible wall is produced than Would other-` wise be possible with a solid sheet. A coveri52 of fabric material may be applied as shown (inserted in flanges 24 or fastened in a suitable manner) in order to conceal the apertured area of the wall.

The modification shown in Figure 7 shows a variation in the construction of a Wall portion where it is not desired` to construct the arcuate wall portion 53 and the flanged portions 54 from one piece of material. The wall portion 53 may be made of one material, preferably a thin sheet or plate of resilient and flexible material as used in the prior forms described for the other views and the flanged portions 54 may be made from the same or different resilient and flexible mate-y rial, as desired. The Wall and flanged portions are attached, joined or secured together by suite` able fastening means, such as rivets, as shown,

the joint being made by bending a portion of wall 52 double to form a pocket 56 adapted to receive and accommodate an extended edge portion of the flange 53, as clearly illustrated. This type of construction lends increased strength to the union or joint of the parts.

vAlthough I have shown the wall sections a made of integral elements (except as shown in Figure 7) it is to be clearly understood the elements of a section may be welded or otherwise secured together.

My invention is relatively simple in character and yet it presents and possesses many advantageous features which make it superior to prior articles or structures of the class described. The most important and essential distinctive feature resides in the inherent characteristic property of the casing always to maintain its original shape or form without any aid from reinforcing members or from the filler or core which it encloses and conceals. The casing or cover according to my invention is accordingly self-supporting and self-shape-maintaining because the lateral Walls I thereof are made of one piece (preferably) of material in the form of a plate or sheet (single or multi-ply) which possesses suincient resiliency and flexibility to render it independent of any extraneous or additional reinforcing elements. The boxing itself is inherently resilient and flexible whereby it maintains and preserves its original shape or form (especially straight edges and flat surfaces) irrespective of repeated compressive actions applied thereto.

Another advantageous feature resulting from the use of the boxing having the construction described is found in the readiness and facility with which the user may remove the top and/or bottom cover portions or ticks from the boxing i for repair, laundry, renovation, airation or replacement thereof. It also permits ready replacement of a filler or interposition of a'pad or rubber sheet or the like for special needs.

It is further apparent that the improvement in my invention provides a casing that is simple and inexpensive to construct, is sturdy yet flexible and resilient, being thus sufficiently supple to yield to compressive actions without acquiring permanent deformation and consequent misshapes and irregularities, an-d is neat and clean as well as ornamental and attractive in appearance. An additional novel feature is the permanency of the boxing unit of the casing and which unit may be used for an indefinite period simply by renewing the top and botto-m covers and/or replacing the filler or core at a fraction of the cost for a completely new casing.

Although a substantially rectangular casing has been illustrated it is to be clearly understood any other shape, form or contour is contemplated by my invention to meet the desired needs. Thus the casing may be circular, semi-circular, triangular, elliptical, arcuate, or other shape, or a combination thereof.

In the description and the claims the terms resilient, flexible andinherent are intended to have their ordinary meanings. Resilient is defined as meaning leaping back, rebounding, recoiling, returning to, or resuming, the original position or shape; elastic or capable of recovering size and shape after deformation. Flexible is defined as meaningcapable of being flexed, or bent; admitting of being turned,` bowed or twisted, without breaking; pliable. Inherent is defined las meaning, involved inthe constitution or essential character of anything; belonging by nature or settled habit; inalienable.

Having thus described a specific embodiment of the invention as applied to a casing for mattresses and the like, it is desired to be understood that the particular structure illustrated, describedand suggested is only typical of applie or scope of the present invention, except as limited by the appended claims.

Having thus described my invention, what I claim is:

l. A shape-retaining casing for a mattress, cushion and analogous article comprising in combination a top tick portion and a bottom tick portion, and a wall unit positioned between said tick portions and including an inherently resilient and flexible metallic member provided with open resilient and flexible marginal channel flanges on its top and bottom edges, said flanges being contiguous to and detachably receiving corresponding marginal edges of said tick portions so as to form a closed casing characterized by effectively tending to maintain its normal shape, said wall unit being provided with means at each Ypredetermined `bend to facilitate flexing of said wall unit when said edges are moved toward each other.

2. A shape-retaining casing for a mattress and analogous article comprising in combination a top tick portion and a bottom tick portion, and a wall unit positioned between said tick portions and including a sheet of inherently resilient and flexible material provided with open resilient and flexible marginal channel flanges on its top and bottom edges, said flanges being contiguous to and receiving corresponding marginal edges of said tick portions so as to form a. closed casing characterized by effectively tending to maintain its normal shape, said wall unit being capable of flexing throughout its length.

3. In a compressible casing for mattresses and analogous articles, a closed wall unit comprising a sheet of inherently resilient and flexible material, said sheet being provided with open resilient and flexible channel flanges on its opposed top and bottom edge portions and being nonrectilinear transversely thereof to facilitate flexing of the wall unit when said top and bottom edge portions are moved toward each other.

4. In a compressible casing for mattresses and analogous articles, a closed wall unit including side walls and bend portions joining same comprising an inherently resilient and flexible metallic sheet, said sheet being provided with open resilient and flexible channel flanges on its opposed top and bottom edge portions and being nonrectilinear transversely thereof and provided with means at each predetermined bend along said opposed top and bottom edge portions to facilitate flexing of said Wall unit when said edge portions are moved toward each other.

5. In a compressible casing for mattresses and analogous articles including a sectionalized wall unit, each section consisting of a sheet of inherently resilient and flexible material, said sheet flanges adapted to receive corresponding rolled edges of top and bottom fabric covers, said wall unit being capable of flexing throughout its length, and means detachably interlocking the ends of adjacent sections. y

6. In a compressible casing for mattresses and analogous articles including a sectionalized Wall unit, each section consisting of an inherently resilient and flexible metallic sheet, said sheet provided on its opposed top and bottom `edge portions With open channel iianges of inherently resilient and exible material, said each section being inwardly concavo-convex 'transverse to said opposed top and bottom edge portions said wall unit being provided with means including a series of transversely extending slits arranged to facilitate flexing of the wall unit..

'7. As an article of manufacture a section of a sectionalized Wall unit for a casing for mattresses and analogous articles, said section consisting of sistingof a sheet of resilient and flexible material and provided on its top and bottom end portions With resilient and flexible slotted flanges and provided further with apertures for lending increased flexibility thereto.

10. As an article of manufacture a section of a sectionalized wall unit for a casing for mattresses and analogous articles, said section consisting of an inherently resilient and iiexible metallic sheet provided on its top and bottom end portions with resilient and exible slotted flanges and provided further with apertures for lending increased flexibility thereto.

ll.` In a compressible casing for mattresses and analogous articles, a side wall unit comprising a sheet of inherently resilient and flexible material, said sheet being provided with open resilient and relatively rigid channel flanges on its opposed top and bottom edge portions, and a center portion arcuately yieldable transversely thereof to facilitate flexing of the wall unit when said top and bottom edge portions are moved toward each other.

12. In a compressible casing for mattresses and analogous articles, a side wall unit comprising a sheet of inherently resilient and flexible material, said sheet being provided with open resilient and flexible channel flanges, on its opposed top and bottom edge portions, and having an intermediate portion arcuate transversely thereof, Whereby to facilitate flexing of the Wall unit when said top and bottom edge portions are moved toward each other.

LEWIS J. BENNETT. 

